Gaging mechanism for compression tool



y 11, 1967 E. H. HORNUNG 3,330,148

GAGING MECHANISM FOR COMPRESSION TOOL Filed Aug. 13, 1964 INVENTOR ELMER H HORNUNG ATTORNEYS United States Patent 3,330,148 GAGING MECHANISM FOR COMPRESSION TOGL Elmer H. Hornnng, St. Louis, Mo., assignor to Jasper Biackburn Corporation, St. Louis, Mo., a corporation of Missouri Filed Aug. 13, 1964, Ser. No. 389,399 6 Claims. (Cl. 72-410) This invention relates generally to improvements in a tool for compressing electrical connectors, and more particularly to an improved gaging mechanism for placing and maintaining the tool in precise alignment.

In the heretofore conventional types of compression tools incorporating a toggle joint and adapted to crimp line wire sleeve connectors into intimate clamping contact with the line wires inserted therein, the tool adjustment was checked by measurement of a specified distance between the handles with the jaw ends just touching by utilizing a separate loose gage bar supplied with the tool. Usually the distance between the handle stops was measured for this purpose. The procedure necessitated a series of alternating independent steps of first adjusting the position of the toggle joint and then checking the distance with the separate gage bar until the correct distance was attained. It will be understood that this was a time-consuming procedure and could not always be made immediately when desired or when needed because of the fact that the gage bar was usually stored separate and apart from the tool. Moreover, because this gage bar was loose, it was subject to being lost or misplaced.

An important object is achieved by making an adjusting gage an integral part of the tool so as to eliminate the possibility of loss or misplacement, and by constructing the gage so that it will continuously indicate the alignment condition of the tool when the jaw ends are just touching and will enable the adjustments to be made continuously while indicating the condition until the tool is brought selectively into correct alignment as indicated by the gage. It is necessary for the tool to be in proper adjustment at all times so that the appropriate and efiective compression will be applied to the connector by the dies.

Another important object is realized by locating the gaging means on the toggle joint between and interconnecting the tool handles, the toggle joint being adjustable to bring the tool into alignment as indicated by the gaging means when the jaw ends are just touching and when the handles are disposed the appropriate distance apart.

Still another important objective is provided by the structural arrangement of a first toggle member on one handle and a second toggle member pivotally mounted to the other handle and pivotally connected to the first toggle member to form a toggle joint between the handles, and of a gaging means on the toggle members aligna'ble to indicate tool alignment, the second toggle member being adjustably movable about its pivot connection to the associated handle to cause such tool alignment.

An important object is afforded in that the gaging means includes a gaging edge on one of the toggle members and a coacting indicator on the other toggle member. Advantageously, the indicator preferably consists of a narrow notch formed in the appropriate toggle member that is alignable with the gaging edge upon adjustably positioning the pivoted toggle member.

Another important objective is attained by constructing one handle to include a handle portion inwardly of the associated handle fulcrum, the handle portion constituting a relatively stationary toggle arm, and by pivotally mounting another toggle arm to the other handle and to the fixed toggle arm to provide a toggle joint between the handle fulcrurns. The gage means is provided on the toggle arms to show the desired spread of the handles when the jaws are just touching. The pivotal position of "ice the pivoted toggle arm is adjustable to adjust the spread of the handles to bring the tool selectively in alignment as indicated by the gage means. The adjusting mechanism is capable of lockin the pivoted toggle arm in the adjusted position to maintain such tool alignment.

Yet another important objective is achieved in that the relatively fixed toggle arm and the pivoted toggle arm overlap, and in that the gage includes a gage edge on one of the toggle arms and a gage indicator on the other toggle arm, both the gage edge and indicator being disposed in the overlapping area so that the gage edge and indicator are alignable upon adjusting the relative positions of the pivotally connected toggle arms.

An important object is to provide a gaging means for a compression tool especially adapted for crimping electrical connectors which is simple and durable in construction, economical to manufacture, highly efiicient in operation, and which can be utilized by anyone with little or no instruction.

The foregoing and numerous other objects and advantages of the invention will more clearly appear from the following detailed description of a preferred embodiment, particularly when considered in connection with the accompanying drawing, in which:

FIG. 1 is a top plan view of the compression tool with the front end of the jaws just touching and with the gaging means aligned to indicate the appropriate tool adjustment;

FIG. 2 is a cross sectional view as seen along line 22 of FIG. 1;

FIG. 3 is a side elevational view as seen from the top of FIG. 1 illustrating the adjusting and locking mechanisrn;

FIG. 4 is a cross sectional view as seen along line 4-4 of FIG. 1;

FIG. 5 is a side elevational view of the gage edge, and

FIG. 6 is a perspective view of the pivoted and adjustable toggle arm.

Referring now by characters of reference to the drawing, and first to FIG. 1, it is seen that the compression tool includes a pair of levers generally indicated at 10 and 11. The lever 10 includes an outer lever arm constituting a jaw 12, and an inner lever arm 13. Similarly, the other lever 11 includes an outer lever arm constituting a cooperating jaw 14, and an inner lever arm 15.

Retained by and between the mating faces of jaws 12 and 14 are a pair of dies 16 and 17. The die 16 is carried by the jaws 12 and 14 near the front ends, the die 16 being capable of compressing a smaller electrical connector than the die 17. The die 17 is located behind the die 16 and is detachably connected to the jaws 12 and 14 so that any one of a selection of such dies 17 may be selectively inserted so as to accommodate electrical connectors of dilferent sizes.

Extending between the levers 10 and 11 are a pair of cross links 2% and 21, one of which is located on each side of the levers 1t and 11. The ends of the cross links 26 and 21 are pivotally connected to each other and to the levers 1t and 11 by bolt and nut connections 22 and 23 constituting fulcrums for the inner and outer lever arms. These cross links 20 and 21 serve to urge the jaws 12 and 14 together in order for the die 16 or 17 to compress an electrical connector located therein when the inner lever arms 13 and 15 are moved away from each other. On the contrary, when the inner lever arms 13 and 15 are moved toward each other, the cross links 2t} and 21 through their fulcrum connections 22 and 23 cause a separation of the jaws 12 and 14 to permit the insertion of an electrical connector between the cooperating die 16 or 17 or to enable removal of the compressed electrical connector from between such jaws 12 and 14.

Operatively connected to the levers and 11 and to each other are a pair of handles generally referred to by 2 4 and 25. The handle 24 includes a gripping portion 26 and a tubular casting portion 27. The front end of handle casting portion 27 is pivotally connected to the inner lever arm 13 by a pivot pin 30, this pivot connection constituting a fulcrum. Extending inwardly from the handle casting portion 27 is a handle stop 31.

'The other handle 25 includes a gripping portion 32 that is attached to a tubular casting'portion'33. The. front end of the handle casting portion 33. is pivotally connected by pivot pin 34 to the inner lever arm 15, the pivot connection constituting a fulcrum. integrally formed on the inside of the handle casting portion 33' is a handle stop 35 aligned directly opposite the other handle stop 31 and adapted to coact and abut therewith to limit the movement of the handles 24 and 25 toward each other. The handle casting portion 33 includes an integral relatively fixed handle portion 36 located inwardly of the pivot pin 34 constituting the handle fulcrum. This fixed i handle portion 36 constitutes a toggle arm ofa toggle joint oper'atively interconnecting the handles 24 and. 25.

Another toggle arm 37 of this toggle joint is pivotally connected by pin 40 to the handle casting portion 27 and is pivotally connected by pivot pin 41 to the cooperating fixed handle portion 36. It will be noted that this toggle joint is provided between the fulcrums of the handles 24 and 25. r

The pivotal position of the pivoted toggle arm 37 can be adjusted and fixed by a pair of'cooperating screws 42 and 43 threadedly'attached and held by the handle casta ing portion 27 and engageable with the toggle arm 37 on opposite sides of the pivot pin 40. These locking and adjusting screws 42 and -43 respectively are threadedly manipulated to adjust the pivotal position of toggle arm 37 when the front ends of the jaws' 12 and 14 are just touching in order to place the tool in alignment, or in other words, to place the spread of thehandles 24 and 25 at the proper distance.

To adjust the toggle. arm 37, first, the locking screw 42 is' backed ofl? and the adjusting screw '43 is engaged with the toggle arm 37 until the desired spacing is realized between the handles 24 and 25. Then, the locking screw 42 is urged tightly against the toggle arm 37 so that the screws 42 and 43 cooperate to retain the toggle arm 37 in its adjusted pivotal position. a

. A gaging means is provided on the toggle joint between a the fulcrums of the handles 24 and 25 in order to determine visually and with considerable accuracy the prop- ;er alignment of the tool when the front ends of the Y jaws 12 and 14 are just touching. This gaging means in-' 4. be provided on the pivoted 36. Under these conditions, the gage edge 44 and notch 45 will operate in exactly the same manner to indicate alignment or misalignment;

It is thought that the usage and the functional advantage of the compression-tool has become fullyap tional view, as isillustrated in FIG. 1, and the handles 24 and are moved toward each other until the front end of the jaws 12 and 14 are just touching lt is then noted whether or not the gage notch .45 is in'alignment with the gage edge 44. If the notch is notaligned with the gage edge 44, the tool is out of adjustment or alignment. This misalignment'of the tool can becaused by 1 different reasons, one of which is the wearing of the pivot pins and bearings forming the fulcrums between' the levers 10 and 11 and between thelevers 10-11 with the associated handles 24-25. The tool 'must be placed in correct alignment before it can be effectively and most efiiciently used tocompress electrical connectors.

To adjust the tool, the locking screw 42 is backed on from engagement With the toggle arm 37 and the pivotal position of toggle arm 37 is'adjusted by manipulation of r the adjusting screw 43. Upon pivotal movement of the pivoted toggle arm 37, the distance between the spread" V handles 24 and 25 is varied until the correct spread or and the gage notch indicate at all times the alignment .condition of the tool, and continuously indicate just what cludes a machined. gage edge 44 formed on' the fixed handle portion 36 in the overlapping area of the fixed handle portion 36 with the toggle arm 37. This gage edge 7 1 44 extends for a distance along the fixed handle portion 36 between the points indicated a and b in'FIGS. 1

and 5. The gage means also includes a notch 45 constituting an indicator formed in the pivoted toggle arm '37 in the overlapping area with the fixed handle portion 36. 7

When the gage notch 45 is visually aligned with the gage edge 44, when the front'ends .of the jaws 12 and. a

. 14 are just touching, the tool is in correct adjustment or alignment. If the notch 45 is misaligned from the gage edge 44 under these conditions, the tool is not in correct alignment, and appropriate steps must be taken to place the tool in alignment before it can be utilized to compress electrical connectors effectively. The pivotal position of the toggle 'arm 37 is adjusted and fixed by manipulation of the locking and adjusting screws 42 and Oftcourse, will be understood that the relative loca- V tions of the gage edge 44 and the gage notch 45 maybe reversed, and effective alignment results will still be distance is realized as is indicated by the alignment of the gage notch 45 with the gage edge 44. When the gaging means indicates tool alignment, the locking screw 42-is tightened so that the screws 42 and 43 coact to fix the toggle arm 37 in the adjusted position.

It will be understood that the pivotal position of the pivoted toggle arm 37 is adjusted continuously by manipulation of the adjusting screw 43 until'tool alignment is attained. There is no need for stopping the adjustment in. order to use a separate gage bar toindicatethe handle.

spread. The gage means constituted by the gage edge 44 adjustments have to be made by the screw 43 in order to bring the tool into correct alignment. 7

Although the invention has been described by making detailed reference to a single preferred embodiment, such detail is to be understood in an instructive, rather than in anyrestrictive sense, many variants being possible within the scope of the claims hereunto appended. I claim as my invention: 7 a 1. In a tool for compressing an electrical connector:- (a) a pair of levers each having a fulcrum and outer and inner lever 'arms, the outer lever arms comprising jaws having oppositely disposed complementary V dies for receiving the connector,

(b) means pivotally connecting the'levers at their ful- (d) means pivotally connectingthe'handles to provide an adjustable toggle joint therebetween, and

(e) gaging means on the toggle joint indicating tool alignment, the toggle joint beingadjustable to bring the tool selectively in alignmentas indicated by the gaging means. W

2. In a tool for compressing an electrical connector: (a) a pair of levers each having a fulcrum and having outer and inner lever arms, the outer lever arms comprising jaws having. oppositely disposed tary dies for receiving the connector,

toggle arm 37 while the gage notch 45 may be placed in thefixed handle portion complemena (b) means pivotally connecting the levers at their fulcrums, the jaws and dies moving inwardly to compress the connector when the inner lever arms are rotated away from each other,

(c) a pair of handles each having a fulcrum,

(d) means pivotally connecting the fulcrums of the handles to the inner lever arms,

(e) means pivotally connecting the handles to provide a toggle joint between the fulcrums of the handles, and

(f) gaging means on the toggle joint indicating tool alignment with the ends of the jaws just touching, the toggle joint being adjustable to bring the tool selectively in alignment as indicated by the gaging means.

3. In a tool for compressing an electrical connector:

(a) a pair of levers each having a fulcrum and having outer and inner lever arms, the outer lever arms comprising jaws having oppositely disposed complementary dies for receiving the connector, the jaws having predetermined contact portions therebetween,

(b) means pivotally connecting the levers at their fulcrums, the jaws and dies moving inwardly to compress the connector when the inner lever arms are rotated away from each other,

(c) a pair of handles pivotally connected to the inner lever arms for rotating the inner lever arms toward or away from each other,

(d) one of the handles including a first toggle member,

(e) a second toggle member pivot-ally mounted to the other handle and pivotally connected to the first toggle member to form a toggle joint between the handles,

(f) gaging means on the toggle members alignable when the predetermined contact portions are just touching to indicate tool alignment, and

(g) means adjustable positioning the second toggle member to bring the tool selectively in alignment as indicated by the gaging means.

4. In a tool for compressing an electrical connector:

(a) a pair of levers each having a fulcrum and having outer and inner lever arms, the outer lever arms comprising jaws having oppositely disposed complementary dies for receiving the connector,

(b) means pivotally connecting the levers at their fulcrums, the jaws and dies moving inwardly to compress the connector when the inner lever arms are rotated away from each other,

(c) a pair of handles pivotolly connected to the inner arms for rotating the inner arms toward or away from each other,

(d) one of the handles including a first toggle member,

(e) a second toggle member pivotally mounted to the other handle and pivotally connected to the first toggle member to provide a toggle joint between the handles,

(f) a gaging means including a gaging edge on one of the toggle members and a coacting indicator on the other toggle member, which are alignable to indicate tool alignment, and

(g) means adjustably positioning and fixing the second toggle member to bring the tool selectively in alignment as indicated by the gaging means.

5. In a tool for compressing an electrical connector:

(a) a pair of levers each having a fulcrum and having outer and inner lever arms, the outer lever arms comprising jaws having oppositely disposed complementary dies for receiving the connector,

(b) means pivotally connecting the levers at their fulcrums, the jaws and dies moving inwardly to compress the connector when the inner lever arms are rotated away from each other,

(c) a pair of handles each having a fulcrum,

(d) means pivotally connecting the fulcrums of the handles to the inner lever arms,

(e) one of the handles including a handle portion constituting a toggle arm fixed inwardly of the associated handle fulcrum,

(f) another toggle arm pivotally mounted to the other handle and pivotally connected to the fixed toggle arm to provide a toggle joint between the fulcrums of the handles,

(g) a gage means on the toggle arms cooperating to show the desired spread of the handles, and

(h) means adjusting the pivotal position of the pivoted toggle arm to adjust the spread of the handles to bring the tool selectively in alignment as indicated by the gage means, the adjusting means selectively locking the pivoted toggle arm in the adjusted position.

6. In a tool for compressing an electrical connector:

(a) a pair of levers each having a fulcrum and each having outer and inner lever arms, the outer lever arms comprising jaws having oppositely disposed complementary dies for receiving the connector,

(b) means pivotally connecting the levers at their fulcrums, the jaws and dies moving inwardly to compress the connector when the inner lever arms are rotated away from each other,

(e) a pair of handles each having a fulcrum,

(d) means pivotally connecting the fulcrums of the handles to the inner lever arms,

(e) one of the handles including a handle portion extending inwardly of the associated handle fulcrum, the handle portion constituting a toggle arm sta tionary relative to the associated handle,

(f) another toggle arm pivotally mounted to the other handle and pivotally connected to the first toggle arm to provide a toggle joint between the fulcrums of the handles,

(g) a gage means on the toggle arms cooperating to show the desired spread of the handles when the ends of the jaws are just touching in order to provide the appropriate compression of the connector by the jaws when the inner lever arms are rotated away from each other,

(h) the gage means including a gage edge on one toggle arm and a notch in the other toggle arm, the edge and notch being alignable when the handles are spread the appropriate distance when the jaws are just touching, and

(i) means adjusting the pivotal position of the pivoted toggle arm to adjust the spread of the handles to bring the gage notch into alignment with the gage edge when the jaws are just touching and hence bring the tool selectively in adjustment, the last said means selectively locking the pivoted toggle arm in the adjusted position to maintain the tool in adjusted alignment.

References Cited UNITED STATES PATENTS 2,838,970 6/1958 Motches et a1. 72-41 0 3,120,772 2/1964 Mixon 81-351 3,182,485 5/1965 Sund 72-410 CHARLES W. LANHAM, Primary Examiner. H. H. HOINKES, Assistant Examiner. 

1. IN A TOOL FOR COMPRESSING AN ELECTRICAL CONNECTOR: (A) A PAIR OF LEVERS EACH HAVING A FULCRUM AND OUTER AND INNER LEVER ARMS, THE OTHER LEVER ARMS COMPRISING JAWS HAVING OPPOSITELY DISPOSED COMPLEMENTARY DIES FOR RECEIVING THE CONNECTOR, (B) MEANS PIVOTALLY CONNECTING THE LEVERS AT THEIR FULCRUMS, THE JAWS AND DIES MOVING INWARDLY TO COMPRESS THE CONNECTOR WHEN THE INNER LEVER ARMS ARE ROTATED AWAY FROM EACH OTHER, (C) A PAIR OF HANDLES PIVOTALLY CONNECTED TO THE INNER LEVER ARMS FOR ROTATING THE INNER LEVER ARMS, (D) MEANS PIVOTALLY CONNECTING THE HANDLES TO PROVIDE AN ADJUSTABLE TOGGLE JOINT THEREBETWEEN, AND (E) GAGING MEANS ON THE TOGGLE JOINT INDICATING TOOL ALIGNMENT, THE TOGGLE JOINT BEING ADJUSTABLE TO BRING THE TOOL SELECTIVELY IN ALIGNMENT AS INDICATED BY THE GAGING MEANS. 